What Is Conventional Sizing and One-Shot Sizing?

Conventional sizing is the traditional method where multiple sizing agents—typically starch, PVA, CMC, binders, waxes, and lubricants—are cooked and applied in a multi-step process to strengthen warp yarns before weaving.

One-shot sizing, also known as single-use textile sizing chemicals, is a simplified technology where all sizing ingredients (starch, softeners, lubricants, binders) are prepared into one ready-to-use formulation. This “single application” approach significantly reduces cooking, preparation time, and operator intervention.

Alpenol produces sustainable and high-efficiency sizing solutions that can be used in both systems depending on yarn type and loom speed—supporting mills that are transitioning to more energy-efficient and clean weaving operations.

What Is Conventional Sizing in Textile Yarn Processing?

Conventional sizing relies on a compound recipe of several individual ingredients cooked together.

Common Ingredients in Conventional Sizing

• Starch

• Polyvinyl alcohol (PVA)

• Carboxymethyl cellulose (CMC)

• Acrylic binders

• Waxes 

• Lubricants

• Antistatic agents

• Softners

Typical Applications

• Medium to coarse cotton yarns

• Denim warps

• Technical textiles requiring high abrasion resistance

• High-speed looms where strong protective films are needed

This method gives excellent control, but requires:

• More energy

• Longer preparation time

• Higher wastewater load (especially when using PVA)

Conventional sizing works exceptionally well for demanding warp yarns such as denim, where Alpenol's high-performance sizing additives improve cohesion and hairiness control, even in harsh weaving environments.

What Is One-Shot Sizing in Textiles & How Is It Performed?

One-shot sizing (also referred to as one-shot textile sizing solutions, one-shot sizing agents in fabric production, or one-time sizing agents in textiles) is a simplified, ready-mixed approach.

How One-Shot Sizing Is Performed

1. Add the one-shot formulation directly to hot or cold water.

2. Heat to activation temperature (lower than conventional).

3. Mix until uniform.

4. Apply sizing in a single pass without separate chemical additions.

5. Dry, stretch, and wind the warp normally.

It reduces:

• Preparation time

• Preparation complexity

• Manpower

• Chemical variability

Alpenol’s eco-friendly one-shot sizing technology supports mills looking for lower environmental load and faster loom setup.

Process Steps: Conventional Sizing vs One-Shot Sizing

Conventional Sizing – Step-by-Step

1. Individual chemicals weighed and prepared

2. Starch cooked separately

3. PVA dissolved at high temperature

4. Lubricants and waxes added sequentially

5. Filtration and homogenization

6. Application through the size box

7. Drying, stretching, and beam winding

One-Shot Sizing – Step-by-Step

1. Add all-in-one formulation

2. Heat and dissolve once

3. Homogenize

4. Apply directly

5. Dry and wind

Conventional → multi-stage
One-shot → single-stage

One-Shot Sizing vs Conventional Sizing: Advantages & Disadvantages

Advantages of One-Shot Sizing

• Lower energy consumption

• Lesser inventory cost

• Reduced cooking time

• High consistency

• Lower viscosity fluctuations

Disadvantages of One-Shot Sizing

• Lesser customizable recipes in mill

• Less control over pick-up and viscosity

• Slightly higher costs

Advantages of Conventional Sizing

• Highly customizable recipes

• Excellent abrasion resistance

• More control over pick-up and viscosity

Disadvantages of Conventional Sizing

• Higher energy use

• More wastewater

• Operational complexity

• Chemical variability if not standardized

• Human Error

• Performance affected by Relative Humidity in loom shed

Alpenol supports both systems by offering high-performance sustainable sizing polymers that reduce COD and improve desizability while maintaining film strength.

Performance Comparison: PVA-Based Conventional Sizing vs Starch-Based One-Shot Sizing

One-shot products containing modified starch + specialty binders offer improved eco-efficiency.

Alpenol’s hybrid starch-polymer one-shot variants combine lower effluent load with enhanced warp strength, making them suitable for broader yarn ranges.

Common Sizing Agents & Additives Used in Conventional and One-Shot Systems

Primary Film Formers

• Starch

• PVA

• Modified starches

• Acrylic polymers

Additives

• CMC (viscosity modifier)

• Waxes (lubricity)

• Softeners

• Antistatic agents

• Wetting agents

These chemicals form the backbone of all sizing chemicals used in textile manufacturing.

Process Parameter Differences: Pickup, Temperature & Solids

The lower solids and streamlined mixing of one-shot systems reduce preparation time—valuable for mills producing frequent style changes.

Why Would a Mill Switch Between Methods?

Switch to One-Shot Sizing When:

• Prioritizing energy savings

• Reducing chemical load

• Reducing inventory costs

• Minimizing manpower

• Want more consistency

Switch to Conventional Sizing When:

• Better control on pick-up and viscosity

• Requiring maximum abrasion resistance

• Want to use customisable recipes

Alpenol offers variants tailored for both methods, giving mills freedom to shift without compromising quality.

Environmental Impact: Wastewater Characteristics

Conventional Sizing

• Higher COD

• Difficult-to-treat PVA polymers

• Increased sludge

One-Shot Sizing

• Better biodegradability

• Easier desizing

• Lower chemical load

Mills adopting Alpenol’s biodegradable and water-based one-shot systems often experience significantly lower effluent treatment cost.

Components of an Ideal Conventional Sizing Recipe

• Film-forming polymer (Starch/PVA)

• Viscosity modifier (CMC)

• Lubricant/wax

• Binder

• Penetration agents

• Antistatic components

• Optional antimicrobial agents

• Softner

The balance between film strength and flexibility is key.

Emerging Trends in Textile Sizing Technology

• Hybrid polymer–starch blends

• Energy-efficient cookers

• Water-based eco-friendly one-shot sizing chemicals

• Zero-PVA universal sizing formulations

• IoT-enabled viscosity monitoring

• Sustainable sizing designed for recycled yarns

Alpenol is also contributing to this movement through bio-based polymer systems and cleaner desizing performance aligned with ZDHC goals.

FAQ

1. What is conventional sizing?

A multi-ingredient sizing method using starch, PVA, CMC, waxes, and lubricants for warp protection.

2. What is one-shot sizing?

A ready-mixed, single-application sizing chemical system that simplifies preparation.

3. Which is better: one-shot or conventional?

One-shot is energy-efficient and simple; conventional offers customisation for various types of recipes.

4. What chemicals are used in sizing?

Starch, PVA, CMC, acrylic binders, waxes, lubricants, wetting agents, softeners and anti-static agents.

5. How does Alpenol fit into the market?

By offering one-shot eco-friendly sizing chemicals that improve warp performance and reduce chemical load, saving the environment for all woven fabrics.

Backlink Sources

• https://textilelearner.net

• https://textiletoday.com.bd

• https://aatex.org

• https://sciencedirect.com

• https://pmc.ncbi.nlm.nih.gov

• https://mdpi.com

• https://fibre2fashion.com